Method for packaging a potted plant

ABSTRACT

The present invention is a modular system for packaging articles for shipment. In particular, a potted plant is placed in a cover, then automatically deposited into a protective sleeve. The potted plant thus packaged is ready for containment within a shipping carton. Various components of the system may be adapted for various packaging needs and circumstances.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. Ser. No. 10/208,566,filed Jul. 29, 2002, now U.S. Pat. No. 6,546,700 which is a continuationof U.S. Ser. No. 09/909,374, now U.S. Pat. No. 6,546,669 filed Jul. 19,2001, which is a continuation of U.S. Ser. No. 09/785,891, filed Feb.16, 2001, now U.S. Pat. No. 6,311,461, which is a continuation of U.S.Ser. No. 09/393,041, filed Sep. 8, 1999, now U.S. Pat. No. 6,189,295,which is a continuation of U.S. Ser. No. 09/005,630, filed Jan. 9, 1998,now U.S. Pat. No. 6,006,500, which is a continuation of U.S. Ser. No.08/720,961, filed Oct. 10, 1996, now U.S. Pat. No. 5,706,628, which is acontinuation of U.S. Ser. No. 08/462,332 filed Jun. 5, 1995, now U.S.Pat. No. 5,605,029, which is a division of U.S. Ser. No. 08/417,477filed Apr. 5, 1995, now U.S. Pat. No. 5,586,425, which is a continuationof U.S. Ser. No. 07/954,635, filed Sep. 30, 1992, now abandoned.

FIELD OF THE INVENTION

The present invention relates generally to a system for packagingarticles for shipment and more particularly, but not by way oflimitation, to a system for automatically packaging potted plants forshipment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of an article packaging system constructed inaccordance with the present invention.

FIG. 2 is a plan view of part of the packaging system of FIG. 1 showingan automated greenhouse.

FIG. 3 is a perspective view of a manual sorting station which may beused in the article packaging system of the present invention.

FIG. 4 is a plan view of an automatic sorting station which may be usedin the article packaging system of the present invention.

FIG. 5 is an elevational view of a gate constructed in accordance withthe present invention.

FIG. 6 is a plan view of one embodiment of a cover placing station whichmay be used with the article packaging system of the present invention.

FIG. 7 is an elevational view of the cover placing station of FIG. 6.

FIG. 8 is an enlarged elevational view of a cover placing sub-unit, inposition to retrieve a cover.

FIG. 9 is the cover placing sub-unit of FIG. 8 in position for receivingan article.

FIG. 10 is the cover placing sub-unit of FIG. 8 shown immediately afterreceiving an article.

FIG. 11 is an elevational view of another embodiment of the coverplacing sub-unit, constructed in accordance with the present invention.

FIG. 11A is a plan view of the cover placing sub-unit shown in FIG. 11.

FIG. 12 is an elevational view of another embodiment of the coverplacing sub-unit, constructed in accordance with the present invention.

FIG. 12A is a plan view of the cover placing sub-unit shown in FIG. 12.

FIG. 13 is a plan view of yet another embodiment of the cover placingsub-unit, constructed in accordance with the present invention.

FIG. 14 is an elevational view of a sleeve constructed in accordancewith the present invention.

FIG. 15 is an elevational view of part of a sleeving station showing asleeve before the sleeve is inflated.

FIG. 16 is a perspective view of part of the sleeving station of FIG. 15showing an inflated sleeve.

FIG. 17 is an elevational view of the sleeving station with partsremoved for clarity.

FIG. 18 is a plan view of the sleeving station.

FIG. 19 is a perspective view of the sleeving station and part of thesealing station.

FIG. 20 is an elevational view showing a sealing and a placing stationconstructed in accordance with the present invention.

FIG. 21 is a plan view showing the sealing and placing station of FIG.20.

FIG. 22 is a schematic of another embodiment of an article packagingsystem constructed in accordance with the present invention.

FIG. 23 is a side view of the packaging system of FIG. 22.

FIG. 24A is a perspective view of a sleeving station which may be usedin an article packaging system of the present invention.

FIG. 24B is a perspective view of the sleeving station of FIG. 24Aindicating a sleeve positioned to receive a potted plant.

FIG. 24C is a perspective view of the sleeving station of FIG. 24A afterthe potted plant has been inserted into the sleeve.

FIG. 24D is a perspective view of the sleeving station of FIG. 24Ashowing the sleeved potted plant pushed onto a conveyor.

FIG. 25 is a perspective view of a sleeving station modified to pushsleeved potted plants directly into a box.

FIG. 26 is a perspective view of a sleeving station modified to transfera sleeved potted plant by lifting it into a box.

FIG. 27A is a perspective view of a sleeving station modified to receivea pot cover prior to receiving a potted plant.

FIG. 27B is a perspective view of the sleeving station of FIG. 27Aprepared to receive the potted plant.

FIG. 28A is an elevational view of a cover supplying device which may beused in an article packaging system of the present invention.

FIG. 28B is a plan view of the cover supplying device of FIG. 28A.

FIG. 29A is an elevational view of another cover supplying device whichmay be used in an article packaging system of the present invention.

FIG. 29B is a plan view of the cover supplying device of FIG. 29A.

FIG. 30A is an elevational view of another cover supplying device whichmay be used in an article packaging system of the present invention.

FIG. 30B is an elevational view of the device of FIG. 30A after a potcover has been picked up.

FIG. 30C is a perspective view of the device of FIG. 30A wherein asleeve is readied to receive the pot cover.

FIG. 30D is a perspective view of the device of FIG. 30A wherein the potcover has been inserted into the sleeve.

FIG. 31 is a plan schematic view of another article packaging system ofthe present invention.

FIG. 32 is an elevational view of a mobile sleeving station for use withan article packaging system such as that in FIG. 31.

FIG. 33 is a plan view of a boxing system for use in an articlepackaging system of the present invention.

FIG. 34 is a plan view of a portion of another article packaging systemin which a cover is applied directly to an article by a cover formingapparatus.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention, an article packaging system, is described hereinas being adapted to process potted plants. However, a potted plantrepresents only one article which can be processed with the presentinvention and the present invention specifically contemplates variousand numerous other types of articles such as: vases, hats (includingcowboy hats, fedoras, caps, derbies, sombreros, fezzes and helmets),rose stem boxes, flower pots, candy trays, baskets (such as Easter ordecorative baskets), corsage boxes, containers, and various otherarticles. The term “article” as used herein is intended to encompass allof the specific articles just mentioned and the term “article” also isintended to be broad enough to encompass any other article which may bedecorated, sleeved, and then packed for shipping.

The term “potted plant” as used herein means a botanical item and thepot, such as a flower pot, within which the botanical item is contained.The potted plant has potting soil or any other growth medium or filler,such as foam, known in the art to secure a plant or other botanical itemwithin a pot. One end of the botanical item is secured in the pot andthe other end exposed through the opening in the flower pot. The pottedplant has an exterior surface comprising the outer surface of the pot,about which a decorative cover may be placed or applied.

The term “botanical item” as used herein means a natural or artificialherbaceous or woody plant, taken singly or win combination. The term“botanical item” also means any portion or portions of natural orartificial herbaceous or woody plants including stems, leaves, flowers,blossoms, buds, blooms, cones, or roots, taken singly or in combination,or in groupings of such portions such as bouquet or floral grouping. Theterm “propagule” as used herein means any structure capable of beingpropagated or acting as an agent of reproduction including seeds,shoots, stems, runners, tubers, plants, leaves, roots or spores. Theterm “growing medium” used herein means any liquid, solid or gaseousmaterial used for plant growth or for the cultivation of propagules,including organic and inorganic materials such as soil, humus, perlite,vermiculite, sand, water, and including the nutrients, fertilizers orhormones or combinations thereof required by the plants or propagulesfor growth. The term “flower pot” means any type of floral containerused to hold a botanical item. Examples of flower pots used inaccordance with the present invention include clay flower pots, plasticflower pots, and flower pots comprised of other natural or syntheticmaterials.

The present invention particularly contemplates the preparation ofpotted plants for shipment. More particularly a potted plant may becovered with a formed sheet of decorative material formed into adecorative cover having an interior surface, exterior surface and aninterior space adjacent and surrounded by the interior surface such asthat formed in a mold type article forming system described in detail inU.S. Pat. No. 4,773,182, issued to Weder et al. on Sep. 27, 1988, andwhich is hereby specifically incorporated herein by reference.

A decorative pattern, such as a color and/or an embossed pattern, and/orother decorative surface ornamentation may be applied to the uppersurface and/or the lower surface of the sheet of material comprising thedecorative cover or portions thereof including, but not limited toprinted design, coatings, colors, flocking or metallic finishes. Thesheet of material comprising the cover also may be opaque, translucent,or totally or partially clear or tinted transparent material.

The sheet of material may be constructed of a single sheet of materialor a plurality of sheets. Any thickness of the sheet of material may beutilized in accordance with the present invention as long as the sheetof material may be wrapped about at least a portion of a flower pot ordeposited within a sleeve, as described herein. The sheet of materialmay have a thickness of less than about 1 mil to about 30 mils.Typically, the sheet of material has a thickness in a range of less thanabout 0.2 mil to about 10 mils. In a preferred embodiment, the sheet ofmaterial is constructed from one sheet of man-made organic polymericfilm having a thickness in a range of from less than about 0.5 mil toabout 2.5 mils.

The sheet of material is constructed from any suitable material that iscapable of being wrapped about a flower pot. Preferably, the sheet ofmaterial comprises paper (untreated or treated in any manner),cellophane, foil, synthetic organic polymeric film, fiber (woven ornonwoven or synthetic or natural), cloth (woven or nonwoven or naturalor synthetic), burlap, or any combination thereof.

The term “synthetic organic polymeric film” means a synthetically maderesin such as a polypropylene as opposed to naturally occurring resinssuch as cellophane. A synthetic organic polymeric film is relativelystrong and not as subject to tearing (substantially non-tearable), asmight be the case with paper or foil. The synthetic organic polymericfilm is a substantially linearly linked. Such films are syntheticpolymers formed or synthesized from monomers. Further, a relativelysubstantially linearly linked processed organic polymeric film isvirtually waterproof which may be desirable in many applicationsinvolving wrapping botanical items or potted plants.

Additionally, a relatively thin film of substantially linearly linkedprocessed organic polymer does not substantially deteriorate insunlight. Processed organic polymeric films having carbon atoms bothlinearly-linked and cross-linked, and some cross-linked polymeric films,also may be suitable for use in the present invention provided suchfilms are substantially flexible and can be made in a sheet-like formatfor wrapping purposes consistent with the present invention. Forexample, one such man-made organic polymeric film is a polypropylenefilm.

The sheet of material may vary in color. Further, the sheet of materialmay consist of designs which are printed, etched, and/or embossed; inaddition, the sheet of material may have various colorings, coatings,flocking and/or metallic finishes, or be characterized totally orpartially by pearlescent, translucent, transparent, iridescent, or thelike, characteristics. Each of the above-named characteristics may occuralone or in combination. Moreover, each surface of the sheet of materialmay vary in the combination of such characteristics.

The sheet of material has a width extending generally between the firstside and the second side respectively, sufficiently sized whereby thesheet of material can be wrapped about and substantially surround andencompass a flower pot. The sheet of material has a length extendinggenerally between the third side and the fourth side, respectively,sufficiently sized whereby the sheet of material extends over asubstantial portion of the flower pot when the sheet of material hasbeen applied about the flower pot in accordance with the presentinvention shown and described in detail herein.

The sheet of material may further comprise at least one scent. Examplesof scents utilized herein include (but are not limited to) floral scents(flower blossoms, or any portion of a plant), food scents (chocolate,sugar, fruits), herb or spice scents (cinnamon), and the like.Additional examples of scents include flowers (such as roses, daisies,lilacs), plants (such as fruits, vegetables, grasses, trees), foods (forexample, candies, cookies, cake), food condiments (such as honey, sugar,salt), herbs, spices, woods, roots, and the like, or any combination ofthe foregoing. Such scents are known in the art and are commerciallyavailable.

The scent may be disposed upon the sheet of material by spraying thescent thereupon, painting the scent thereupon, brushing the scentthereupon, lacquering the scent thereupon, immersing the sheet ofmaterial to scent-containing gas, or any combination thereof.

The scent may be contained within a lacquer, or other liquid, before itis disposed upon the sheet of material. The scent may also be containedwithin a dye, ink, and/or pigment (not shown). Such dyes, inks, andpigments are known in the art, and are commercially available, and maybe disposed upon or incorporated in the sheet of material by any methoddescribed herein or known in the art.

The decorative cover may be bonded to the article or potted plant by abonding material. The term “bonding material” as used herein means anadhesive, preferably a pressure sensitive adhesive, or a cohesive. Wherethe bonding material is a cohesive, a similar cohesive material must beplaced on the adjacent surface for bondingly contacting and bondinglyengaging with the cohesive material. The term “bonding material” alsoincludes materials which are heat sealable, sonic sealable and,vibratory sealable in these instances, the adjacent portions of thematerial must be brought into contact and then heat, sound waves orvibrations, respectively, must be applied to effect the seal.

The term “bonding material” as used herein also means a heat sealinglacquer which may be applied to the sheet of material and, in thisinstance, heat also must be applied to effect the sealing. The term“bonding material” as used herein means any type of material or thingwhich can be used to effect the bonding or connecting of the twoadjacent portions of the material or sheet of material to effect theconnection or bonding described herein. The term “bonding material” alsoincludes ties, labels, bands, ribbons, strings, tape, staples orcombinations thereof.

The decorated article covered with a decorative cover may then be placedin a sleeve to generally protect it during shipping. For example, apotted plant may be sleeved to preserve water and carbon dioxide for theplant, and to protect the plant during shipping. The sleeve may be madefrom an impermeable material which would retain all gases and liquids orfrom a semi-permeable material, such as a material which would allowoxygen and carbon dioxide to pass, but would inhibit the passage ofwater through the material.

Sleeves are well known in the art of packaging potted plants. As usedherein, a sleeve is cylindrical, conical or frusto-conical in shape andhas an upper opening, which provides an opening for the deposit of apotted plant, or other article, therein. Sleeves may be comprised of anyflexible material suitable for covering a potted plant, includingmaterials selected from a group of materials, comprising paper, metal,foil cloth (natural or synthetic), denim, burlap, or polymeric film, orcombinations thereof. The term polymeric film as used herein means anypolymeric film, including for example, but not by way of limitation,polypropylene film and cellophane. The material comprising the sleevemay be opaque, translucent, or totally or partially transparent and maybe decorated with designs or tints.

The article, after having been placed in a sleeve, may then be placed ina container for shipping. The container, such as a box, carton or crate,may then be sealed and marked for easy identification. The presentinvention provides an automated line for preparing articles for shippingin the manner just described thereby saving the seller considerablelabor expense and reducing the preparation time required for packagingarticles.

In describing the preferred embodiment, a potted plant will be used asan example of the article being processed. However, as discussed abovethe invention may be used on various other articles.

Embodiment of FIGS. 1-21

Turning now to FIG. 1, an article packaging system designated by thereference numeral 10 is shown which is constructed in accordance withthe present invention. The article packaging system 10 is adapted totransport an article from a storage location, place a decorative coverover or around the article, place the covered article in a sleeve, andpack the sleeved article in a carton for shipping.

A storage location such as a greenhouse, hereby designated by thereference numeral 12, supplies potted plants 14 (FIG. 3) for processing.The greenhouse 12 is a frame covered with a material which will allowthe radiant energy from the sun to reach the potted plants 14 which aregrown inside. Such structures are common in the art. Within thegreenhouse 12 are growing racks 16 (FIG. 2) adapted for holding thepotted plants 14 while they are grown. The greenhouse 12 may beautomated by installing conveyors 18 and 20 (also shown in FIG. 2)adapted for transporting the potted plants 14 into and out of thegreenhouse 12. Conveyors 18 and 20 may also serve as additional growingracks. Each conveyor 18 or 20 should be reversible so it may serve tobring potted plants 14 into the greenhouse 12 or supply potted plants 14from the greenhouse 12. Each conveyor 18 or 20 may be similar inconstruction. The construction details of the conveyors 18 and 20 arenot required herein as they are well known to persons of ordinary skillin the art.

As indicated in FIG. 1, a conveyor 22 extends from the greenhouse 12 toa sorting station 24. The sorting station 24 may be a manual sortingstation 26 (FIG. 3) or an automatic sorting station 28 (FIG. 4). Themanual sorting station 26 comprises a table 30 which receives the pottedplants 14 from the conveyor 22. An operator (not shown) standing nearthe table 30 may select the potted plant 14, in accordance with apredetermined grading criterion such as size and grade, and place it ona conveyor 32 or a conveyor 34 with other potted plants (not shown) of asimilar grade. The potted plants 14 are sorted into one of at least twogrades. Conveyors 32 and 34 should begin near the manual sorting station26 and transport the potted plants 14 to the next area for furtherprocessing.

In an alternative embodiment (not shown), the manual operator at themanual sorting station 26 may select potted plants 14 directly from theconveyor 22 and grade and place them directly from the conveyor 22 toconveyors 32 and 34, thereby eliminating the need for the table 30.

In the automatic sorting station 28 of FIG. 4, the automatic sortingstation 28 may be any one several apparatuses for sorting the pottedplants 14. One embodiment of the automatic sorting station 28 is shownin FIG. 4 and comprises a first positioning gate 36 and a secondpositioning gate 38, a light source assembly 40, a light sensor assembly42 which is comprised of at least one sensing device such as aphotoelectric cell 43 and a support backing 44, a light switch 45 and agate 46, all located near the discharge end of the conveyor 22.

Referring now to FIGS. 4 and 5, the first and second positioning gates36 and 38 are similar in construction. Each positioning gate 36 and 38has an arm 48 (FIG. 5). The arm 48 is preferably made from a strip ofstainless steel about four to eight inches tall and of sufficient lengthto reach half way across conveyor 22. One end of the arm 48 is securedas by welding to a rod 50. The rod 50 extends up from the arm 48 througha bearing 52, to a motor 54. A collar 56 is secured to the rod 50 abovethe bearing 52 by a set screw 58, thereby holding the arm 48 off theupper surface of the conveyor 22. The bearing 52 is secured to a brace60 which is mounted to the side of the conveyor 22.

The first and second positioning gates 36 and 38 are secured to oppositesides of the conveyor 22 and they work in conjunction to release pottedplants 14 at regular intervals. In addition to spacing the potted plants14 along the conveyor 22, the first and second positioning gates 36 and38 also position the potted plants 14 generally in the center ofconveyor 22. Therefore, all potted plants 14 are positionedapproximately the same distance from the light sensor assembly 42 asthey pass in front of it.

With continued reference to FIG. 4, the light source assembly 40 iscomprised of a housing 62 having a slot 64 formed on the side adjacentthe conveyor 22. The housing 62 is secured on one side of the conveyor22 such that the slot 64 is on the side of the housing 62 which facesthe conveyor 22. At least one light source 66, such as a light bulb, issecured within the housing 62 so that light emitted by the light source66 passes through the slot 64 and across the conveyor 22.

Directly across conveyor 22 from the light source assembly 40 is thelight sensor assembly 42.

The light switch 45 is located in front of the light source assembly 40and turns on the light source 66 when the potted plant 14 is between thelight source assembly 40 and the light sensor assembly 42. Since thepotted plant 14 is between the light source assembly 40 and the lightsensor assembly 42 when the light source 66 is turned on, the amount oflight reaching the light sensor assembly 42 depends upon the size anddensity of the foliage on the potted plant 14. The taller and more densethe foliage, the less light reaches light sensor assembly 42.

The gate 46 is located downstream from the light sensor assembly 42 nearthe end of the conveyor 22. The gate 46 is similar in construction tothe first positioning gate 36. The brace 60 of gate 46 is positionedover the center of the conveyor 22. The gate 46 is pivoted to a firstposition 68 or a second position 70 depending on the amount of lighthitting the light sensor assembly 42. The action of the gate 46 iscontrolled by a control assembly (not shown) which detects the degree oflight detected by the photoelectric cell 43 and responds accordingly.

While the potted plant 14 is between the light source 66 and thephotoelectric cell 43, the potted plant 14 may be rotated by a rotatingdevice (not shown). In this way light can be sensed and measured atseveral points of rotation of the foliage of the potted plant 14,thereby measuring an average amount of detected light which may providea more accurate grading system for the foliage of the potted plants 14.Alternatively, instead of being rotated, several light readings could bemeasured at several points along the conveyor 22, for example, with thelight readings taken at different angles to the foliage, to derive anaverage of the several readings.

Directly downstream from the gate 46 is a positioning bar 72. Thepositioning bar 72 is V-shaped and is positioned so the point of the Vis directly downstream from the brace 60 of the gate 46. A first end 74and a second end 76 of the bar 72 extend off a side of the conveyor 22and onto an adjacent conveyor 32 or 34. The first end 74 of the bar 72extends from the conveyor 22 to the conveyor 34. The second end 76 ofthe bar 72 extends from the conveyor 22 to the conveyor 32. Conveyors 32and 34 may lead to similarly constructed processing lines and thus, onlyone such line is described below.

In an alternative embodiment (not shown), the potted plants 14 can begraded on the basis of the difference between a known tare weight of thepot and soil and the weight of potted plant 14. If the tare weight ofthe pot and saturated soil contained therein is known, this measurementcan be subtracted from the weight of a potted plant having saturatedsoil. The difference in weight is an approximate measure of the weightof the plant. This enables the classification, or grading, of the pottedplant 14 on the basis of the criterion of weight, rather than of thebasis of the amount of light reaching a light sensor 42, whichrepresents foliage density.

Other automatic methods of grading the potted plants 14 are to use otherforms of electromagnetic radiation such as radar (not shown) or aninfra-red light sensing device (not shown) which grades the plant bydetecting the amount of heat the plant gives off.

The embodiment of the article processing system described hereinenvisions only a single sorting station 24 to grade the potted plants14. However, it will be appreciated by one of ordinary skill in the artthat additional sorting stations 24 could be located downstream ofeither conveyor assemblies 32 or 34 to provide additional grading of thepotted plants 14.

The conveyor 32 moves the potted plants 14 to a covering station 82. Thecovering station 82 may be embodied in a variety of different forms asdescribed and shown below.

In the embodiment shown in FIGS. 6 and 7, the covering station 82includes a first gate 84 and a second gate 86, a turnstile 88 and acover denesting sub-unit 90. The first and second gates 84 and 86 aresecured to opposite sides of the conveyor 32 and work in conjunction torelease potted plants 14 at regular intervals. In addition to spacingthe potted plants 14 along the conveyor 32, the first and second gates84 and 86 also position the potted plants 14 in the center of conveyor32. Therefore, all potted plants 14 are positioned to be received by theturnstile 88.

The turnstile 88 and the cover denesting sub-unit 90 may be mounted on aplatform 92 with a plurality of locking casters 94 (FIG. 7). Thus, theturnstile 88 and the cover denesting sub-unit 90 may be rolled to theside and replaced with a section of conveyor (not shown) when coveringthe article is not a required step.

The turnstile 88 has a conduit 98 with a first end 100 and a second end102. The first end 100 is secured to the platform 92. The turnstile 88has a turnstile axle 104 which has a first end 106 and a second end 108.The second end 102 of the conduit 98 is open for accepting the first end106 of the turnstile axle 104. The diameter of the first end 106 of theturnstile axle 104 is slightly smaller than the diameter of the lumen inthe conduit 98. This allows the turnstile axle 104 to rotate freelywithin the conduit 98.

A drive assembly mount 110 is secured near the second end 102 of theconduit 98. Secured to the drive assembly mount 110 is a drive assembly112 with a rotatable shaft 114. Secured to the rotatable shaft 114 is afirst gear 116. A second gear 118 is secured to the turnstile axle 104between the first end 106 and the second end 108 thereof, and in aposition such that the first gear 116 and the second gear 118 mesh.

Secured near the second end 108 of the turnstile axle 104 are fourtransfer assemblies 120A, 120B, 120C and 120D. Each transfer assembly120A-120D includes a carrying unit 121, a brace 122, and a cylinder 123.The brace 122 has a first end 124 and a second end 125. Each carryingunit 121 comprises a first arm 126 and a second arm 128 (FIGS. 6-7).

The first end 124 of the brace 122 is secured to the turnstile axle 104and is adapted for supporting the cylinder 123. The cylinder 123 issecured to the second end 125 of the brace 122.

Secured to the cylinder 123 are the first and second arms 126 and 128 ofthe carrying unit 121. The cylinder 123 is adapted to reciprocatinglyraise and lower the carrying unit 121.

Referring now to FIGS. 6-10, also secured to the platform 92 is anautomatic cover supplying assembly, also referred to as the coverdenesting sub-unit 90. The cover denesting sub-unit 90 includes a coverdispenser housing 130 and a cover dispenser support 132 (FIGS. 8-10)having a base 133. The cover dispenser support 132 is adapted forsupporting the cover dispenser housing 130 over the platform 92. Thecover denesting sub-unit 90 also includes a conveyor with a firstparallel belt 134 and a second parallel belt 136. The first and secondparallel belts 134 and 136 are placed around rollers 138 and 140 (FIG.7), and are spaced apart to provide a gap 142 lengthwise for enablingthe placement of a retrieved cover into a potted plant applicationposition.

A conveyor 144 having a first end 146 and a second end 148 (FIG. 19) isabutted at its first end 146 to the end of the belts 134 and 136 in aposition to receive a cover 158 or a covered potted plant from belts 134and 136.

A suction support arm 150 is generally L-shaped and is pivotally securedat a first end 151 near the base 133 of the cover dispenser support 132.The suction support arm 150 has a free end 153.

A cylinder 152 extends between the platform 92 and the suction supportarm 150 and is slidingly secured to the suction support arm 150 by abracket 154. The cylinder 152 and bracket 154 are adapted for raisingthe suction support arm 150 so a suction cup 156, which is connected tothe free end 153 (FIG. 8) of the suction support arm 150, is raised to aposition for removing the cover 158 (FIGS. 8-10) from the coverdispenser housing 130.

Secured to the platform 92 directly below the suction support arm 150 isa vacuum valve 160 and a support spring 162. A vacuum line 164 extendsfrom the suction cup 156 to the vacuum valve 160 and on to a vacuumsource (not shown). Operational details of the cover denesting subunit90 are described below in the In Operation section.

An alternate cover denesting sub-unit (automatic cover supplyingassembly) embodiment, herein designated by the reference numeral 90A, isshown in FIGS. 11-11A. This embodiment uses an article forming system165, such as is disclosed in U.S. Pat. No. 4,773,182, the specificationof which is hereby incorporated herein by reference. The article formingsystem 165 places covers on a suction cup 156A. The suction cup 156A issupported by a rod 166 which extends up between a first parallel belt134A and a second parallel belt 136A in a fashion similar to the suctionsupport arm 150 described above. This embodiment also includes a vacuumvalve 160A and a support spring 162A.

Another cover denesting sub-unit embodiment, herein designated by thereference numeral 90B, is shown in FIGS. 12 and 12A. In this embodiment,the article forming system 165 places a cover (not shown) on a table168, and a turnstile (not shown), then places a potted plant (not shown)into the cover (not shown) Alternatively, a potted plant may be placedmanually within the cover. A pusher assembly 170 comprised of a cylinder171 and a pushing arm 172 then pushes the covered potted plant (notshown) onto the conveyor 144.

Another cover denesting sub-unit embodiment, herein designated by thereference numeral 90C, is shown in FIG. 13. The cover denesting sub-unit90C uses a first gate 174 and a second gate 176 to hold a cover (notshown) stationary on the moving conveyor 144. Once the potted plant (notshown) is in the cover (not shown), the first and second gates 174 and176 open, allowing the covered potted plant (not shown) to proceed downconveyor 144 for further processing.

At some point after the cover 158 has been denested and positioned, apotted plant 14 is placed into the interior space of the cover 158producing a covered potted plant 180 (FIG. 7). The potted plant 14 maybe placed into the cover 158 manually or automatically (non-manually).The covered potted plant 180 is conveyed down conveyor 144 toward thesecond end 148, where it is transferred to an automatic sleeving station184 for application of a sleeve about the covered potted plant 180 toform a sleeved covered potted plant.

Referring now to FIGS. 1 and 17-19, the sleeving station 184 includes aguiding assembly comprising a first spring-loaded guide 186 and a secondspring-loaded guide 188. The first and second spring-loaded guides 186and 188 (FIG. 18) receive the covered potted plant 180 as it moves fromthe second end 148 of the conveyor 144. A brace 190 is secured above thefirst and second spring-loaded guides 186 and 188 to keep the pottedplant 180 upright as it moves in direction 192 (FIG. 17) through thefirst and second spring-loaded guides 186 and 188. Below the first andsecond spring-loaded guides 186 and 188 are a first wicket 194 and asecond wicket 196 for holding a plurality of sleeves, such as a sleeve198 (FIGS. 14-16) and described in detail below. Each wicket 194 and 196has a first end 200 and a second end 202 (FIG. 19). The first end 200 issecured to a brace (not shown) and extends downwardly at an angle to apoint 206 between the first end 200 and the second end 202. From thepoint 206 to the second end 202, the wickets 194 and 196 extendhorizontally or slightly downward.

As is shown in FIGS. 14-16, each sleeve 198 has a front side 208 havinga height 210, and a back side 212 having a height 214. The height 210 ofthe front side 208 of the sleeve 198 is less than the height 214 of theback side 212 of the sleeve 198. Holes 216 and 218 are formed in theupper corners of the back side 212 of each sleeve 198. Although thesleeve 198 is shown in FIGS. 14-17 as tubular, the shape of the sleeve198 may be any variety of shapes but the preferred embodiment isfrusto-conical. Additionally, in an alternative embodiment, heights 210and 214 may be the same and the holes 216 and 218 may extend throughboth the front and back sides 208 and 212 of each sleeve 198.

Referring now in particular to FIGS. 15 and 16, the first and secondwickets 194 and 196 extend through the holes 216 and 218, respectively,to support the sleeve 198. The wickets 194 and 196 are secured so thatthe sleeve 198 is pulled by gravity down the first and second wickets194 and 196 until the backside 212 of the sleeve 198 comes into contactwith an automatic sleeve opening assembly comprising an inflator tube220 (FIG. 16). Air exiting the inflator tube 220 opens and inflates thesleeve 198.

In an alternative embodiment of the sleeve opening assembly, suctioncups (not shown) may be employed to pull open the front side 208 of thesleeve 198 to allow the air blast from the inflator tube 220 and to moreeasily access and open the sleeve 198.

As the covered potted plant 180 reaches the end 148 of the conveyor 144and moves in direction 192 through the chute between the first andsecond spring-loaded guides 186 and 188 and the brace 190, it isdeposited into the open sleeve 198 (FIG. 19) to provide a sleeved pottedplant 222 (also referred to in this instance as a sleeved covered pottedplant).

In an alternative embodiment (not shown), the covered potted plant 180may be formed into the sleeved covered potted plant 222 by wrapping asheet of sleeving material (not shown) about the covered potted plantautomatically.

Referring now to FIGS. 1, 20 and 21, a gripping station 230, alsoreferred to as a transfer station, is positioned to remove the sleevedpotted plant 222 from the first and second wickets 194 and 196. Thegripping station 230 comprises a turnstile 234, a first gripping arm 236and a second gripping arm 238. The turnstile 234 further comprises aconduit 240 with a first end 242 and a second end 244. The first end 242of the conduit 240 is secured to a base 246. The second end 244 of theconduit 240 is open for accepting a first end (not shown) of a turnstileaxle 250. The turnstile axle 250 has a first end (placed inside theconduit 240) and a second end 254. The diameter of the turnstile axle250 is slightly smaller than the diameter of the opening in the conduit240. This allows the turnstile axle 250 to rotate freely within theconduit 240.

A drive assembly bracket 256 is secured near the second end 244 of theconduit 240. Secured to the drive assembly bracket 256 is a driveassembly 258, such as a motor. The drive assembly 258 has a rotatableshaft 260. Secured to the rotatable shaft 260 is a first gear 262. Asecond gear 264 is secured to the turnstile axle 250 in a position suchthat the teeth on the first gear 262 mesh with teeth of the second gear264.

Secured to the second end 254 of the turnstile axle 250 are support arms266A, 266B, 266C and 266D. Each support arm 266A-266D includes the firstgripping arm 236 and the second gripping arm 238. Connected to eachsupport arm 266A-266D is a cylinder 270 adapted for closing the firstgripping arm 236 and the second gripping arm 238 together against theupper end of the sleeve 198 of the sleeved potted plant 222.

In an alternative embodiment, the first gripping arm 236 includes aheating element (not shown) adapted to seal the upper end of the sleeve198 of the sleeved potted plant 222 when the upper end is compressedbetween the first and second gripping arms 236 and 238 thereby forming asealed sleeved potted plant 272. The first and second gripping arms 236and 238 grasp the sealed sleeved potted plant 272, thereby freeing thesealed sleeved potted plant 272 from the first and second wickets 194and 196. From there, the support arm 266 carries the sealed sleevedpotted plant 272 to a placing station 274 (FIGS. 1, 20-21). The upperportion of the sleeve 198 may alternately be sealed by first and secondgripping arms 236 and 238 which comprise sonic elements, vibratoryelements or pressure-sensitive elements.

Positioned to receive the sleeved potted plant 222 or the sealed sleevedpotted plant 272 is the placing station 274 (FIGS. 20-21). The placingstation 274 comprises a lowering arm 276, a first pinching arm 278, asecond pinching arm 280 and a cylinder 282.

The lowering arm 276 is reciprocatingly secured to the cylinder 282 suchthat the lowering arm 276 may be reciprocatingly lowered and raised. Thefirst pinching arm 278 is pivotally secured opposite the second pinchingarm 280 of the lowering arm 276. The first and second pinching arms 278and 280 first receive the sleeved potted plant 222 or the sealed sleevedpotted plant 272 at a receiving position 284 (FIG. 21). A small cylinder288 is secured between the lowering arm 276 and the first pinching arm278. The cylinder 288 is adapted to allow the first and second pinchingarms 278 and 280 to grasp and release the sealed sleeved potted plant272 or the sleeved potted plant 222.

The cylinder 282 is suspended from a rail 290. The rail 290 has a firstend 292 and a second end 294. Secured to the first end 292 of the rail290 is a motor 296 with rotatable shaft 298. Secured to the rotatableshaft 298 is a sprocket 300. On the second end 294 of the rail 290 is anidler sprocket 302. A continuous loop of chain 304 extends around thefirst sprocket 300 and the second sprocket 302. The cylinder 282 issecured to the chain 304 so that upon rotating the shaft 298, thecylinder 282 is moved along the rail 290 to a predetermined position forlowering the grasped sleeved potted plant 222 or the sealed sleevedpotted plant 272 into a box or carton 306.

A carton placing conveyor 308 is adapted to move the carton 306 intoposition for receiving the sleeved potted plant 222 or the sealed sleevepotted plant 272. Once the carton 306 is full the conveyor 308 removesthe carton 306 from the packing area. Cartons, like carton 306, aresupplied from a carton folding station 310 (FIG. 1). Many commerciallyavailable carton folders are suitable, and therefore, need not bedescribed herein. Alternatively, cartons 306 may be supplied manually.

In Operation

Articles 14, which may be potted plants as shown, for example in FIG. 3,are placed on the conveyor 22, then are moved to the sorting station 24(FIG. 1). If the sorting station 24 is a manual sorting station 26, suchas shown in FIG. 3, an operator (not shown) will select articles 14 tobe packaged together, and place them on the conveyor 32 or 34, whichwill carry the articles 14 to the next station.

If the sorting station 24 is the automatic sorting station 28, such asshown in FIG. 4, the articles 14 will travel down conveyor 22 until theycome in contact with positioning gates 36 and 38. The positioning gates36 and 38 will hold an article 14 until a predetermined distance 312between the article 14 and a previous article 14 a has been achieved.Once the distance 316 between the article 14 and the previous article 14a has been achieved, positioning gates 36 and 38 will open allowing thearticle 14 to proceed on to the light sensor assembly 42.

Since the first and second positioning gates 36 and 38 opensimultaneously, the article 14 will be centered on the conveyor 22, andthus, all articles 14 will be the same distance from the light sensorassembly 42 as they pass in front of it. As the article 14 passes infront of the light sensor assembly 42, the article 14 comes into contactwith and moves the light switch 45. Movement of the light switch 45activates the light source 66 in the housing 62.

Light leaving the housing 62 through the slot 64 will be partiallyabsorbed and partially reflected by the article 14. Thus, the larger andmore dense the article 14, the less light will reach the photoelectriccell 43. In this way, smaller or less dense articles 14 may bedistinguished from larger or denser articles 14. If the article 14 issmall, the gate 46 will swing into the first position 68 and if thearticle 14 is large, the gate 46 will swing into the second position 70,as determined by a control assembly (not shown). As the article 14 comesinto contact with the gate 46, it is directed to one side of thepositioning bar 72. The positioning bar 72 further directs the article14 onto an adjacent conveyor, such as conveyor 32. Alternately, thearticle 14 may be sorted after a decorative cover has been applied.

If the article 14 is to receive a decorative cover, which in the case ofa potted plant would be a flower pot cover, the covering station 82 willbe positioned at the end of the conveyor 32. The article coveringstation 82 is mounted on the platform 92 with the locking casters 94.Thus, if no covering is required, the covering station 82 may simply berolled to the side and a section of conveyor (not shown) may take itsplace. Assuming that covering is desired, any of the several embodimentsmay be used with ease.

In the preferred operational embodiment, the article 14 will firstencounter the first and second gates 84 and 86 (FIGS. 6-7). The firstand second gates 84 and 86 hold the article 14 until the turnstile 88 isin position to accept the article 14, that is, when transfer assembly120A is in line with conveyor 32. As soon as the article 14 has enteredthe arms 126 and 128 of the carrying unit 121, the carrying unit 121 israised by the cylinder 123 and the turnstile 88 begins to turn in acounterclockwise direction 314 (FIG. 6).

When the transfer assembly 120A is in a position 316 (FIG. 6), thesuction support arm 150 is raised by the cylinder 152 (see FIG. 8). Bythe time the transfer assembly 120A has reached a position 318, thesuction support arm 150 has been lowered by the cylinder 152, suctionlybringing with it the cover 158 from the cover dispensing housing 130(see FIG. 9). When the transfer assembly 120A reaches a position 320(FIG. 6), the turnstile 88 momentarily stops over the cover 158 whilethe cylinder 124 lowers the carrying unit 121, thereby lowering thearticle 14 into the cover 158. The weight of the article 14 and cover158 depress the support spring 162, thus lowering the covered article180 onto conveyor belts 134 and 136 (see FIG. 10).

As the support spring 162 is depressed, the vacuum valve 160 isdeactivated, thereby causing the suction cup 156 to release the cover158 and allowing the covered article 180 to rest upon the conveyor belts134 and 136. The conveyor belts 134 and 136 direct the covered article180 toward conveyor 144 (FIG. 7), and thus out of the carrying unit 121.As the turnstile 88 resumes rotation, and as the transfer assembly 120Apasses through a position 322 (FIG. 6), cylinder 124 retracts thecarrying unit 121, thereby raising the first arm 126 and the second arm128 of the carrying unit 121 into position for receiving the nextarticle 14 from the conveyor 32.

The covered article 180 is directed from the first and second parallelbelts 134 and 136 to the conveyor 144 (FIG. 7), and continues to thesleeving station 184 (FIG. 17). As the covered article 180 reaches thesecond end 148 of the conveyor 144, it drops gravitationally through thepair of spring-loaded guides 186 and 188 (FIG. 18). The brace 190supports the upper side of the covered article 180 as it drops from theconveyor 144 thereby maintaining the vertical positioning of the coveredarticle 180 as it drops. The spring-loaded guides 186 and 188 guide thecovered article 180 into the opened sleeve 198 (FIG. 19).

As is shown in FIG. 16, a supply of sleeves 198 is supported on wickets194 and 196, and are gravitationally fed to the inflator tube 220. Theend of the inflator tube 220 comes into contact with the back side 212(FIG. 16) of the first sleeve 198 in the supply, thus keeping the supplyof sleeves 198 from sliding down the wickets 194 and 196. Air exitingfrom the inflator tube 220 inflates the lowermost sleeve 198 inpreparation for receiving a covered article 180. The added weight of thecovered article 180 dropping from the conveyor 144 causes the openedsleeve 198 to sag, thus releasing it from the inflator tube 220 andenabling it to slide down wickets 194 and 196 to the horizontal sectionof the wickets 194 and 196 (FIG. 19). After the first sleeve 198 isremoved another sleeve 198 moves into position to be inflated. The firstsleeve 198 containing the covered article 180, now constituting asleeved covered article 222, is grasped by first and second grippingarms 236 and 238 (FIG. 19) of the gripping (transfer) station 230 (FIGS.20 and 21).

The turnstile 234 then rotates, thus pulling the sleeve 198 from thewicket 194 and 196. In one embodiment, as the turnstile 234 continues torotate, heating elements (not shown) in the first gripping arm 236 heatthe gripped portions of the sleeve 198, sealing the front and the backsides 208 and 212, respectively, of the sleeve 198 of the sleevedcovered article 222 (FIG. 21) to form the sealed sleeved covered article272. In one version, the sleeve 198 is not sealed over the sleevedcovered article 222. As the turnstile 234 rotates 180 degrees to thereceiving position 284, the first and second gripping arms 236 and 238,still carrying the sleeved covered article 222 or the sealed sleevedarticle 272 (as the case may be), move between the first pinching arm278 and the second pinching arm 280 of the placing station 274 (FIGS.20-21).

Once the first and second gripping arms 236 and 238 are between thefirst pinching arm 278 and the second pinching arm 280, the first andsecond pinching arms 278 and 280 close to pinch the sleeve 148 of thesleeved covered article 222 or of the sealed sleeved covered article 272(as the case may be) and the first and second gripping arms 236 and 238are opened slightly. Thus, the sleeved potted plant 222 or the sealedsleeve potted plant 272 is now held by the first and second pinchingarms 278 and 280 of the placing station 274. Immediately thereafter, thecylinder 282 is pulled along the rail 290 via the motor 296 and chain304 (FIGS. 20-21) from the receiving position 284 to the position 326and the sleeved potted plant 222 or the sealed sleeved potted plant 272is lowered into the carton 306. The first and second pinching arms 278and 280 are then released and the lowering arm 276 is raised andreturned to the receiving position 284 to accept the next sleeved pottedplant 222 or sealed sleeved potted plant 272.

Each sleeved potted plant 222 or sealed sleeved potted plant 272 isreceived and placed in the carton 306. Placing of the article 222 or 272in the carton 306 may be manually or automatically controlled (controlmechanism not shown). The conveyor 308 moves as necessary to allowplacing of the sleeved potted plant 222 or the sealed sleeved pottedplant 272 in the carton 306.

This cycle repeats until the carton 306 is full. At that time, conveyor308 carries away the full carton 306 and replaces it with a newcontainer 306. The full carton 306 eventually reaches a carton closingstation 330 (FIG. 1) and then a carton labeling station 332 (FIG. 1),where machines of construction well known to those of ordinary skill inthe art close and label the carton 306. The carton 306 is then ready forshipment.

Embodiment of FIGS. 22-34

Attention is now directed to article packaging system designated by thereference numeral 350 and represented in FIGS. 22 and 23. The articlepackaging system 350 is a processing line for sorting articles, forexample in this case potted plants 352, according to size, quality, orother criteria and then for processing and packaging the processedplants. The article packaging system 350 automatically (non-manually)places a covered potted plant into a protective sleeve and [would] then[place] places the sleeved pot into a box or carton for shipping anddistribution.

In overview, the article packaging system 350 comprises a servicestation 356 having a platform or table 358 serving to support a set ofunsorted potted plants 352. A sorting station 360 employs a sorter whichinspects the potted plants 352 and sorts them in accordance withpredetermined criteria such as size, quality or variety or any number ofother criteria. The sorting station 360 may be manually operated likethe sorting station 26 described herein or it may operate automatically,for example, like the automatic sorting station 28 described herein.

A cover supplying station 362 comprises an automatic cover supplyingassembly 364 (FIGS. 28A-B) for selecting a pot cover 366 and placing thepot cover 366 in an application position for receiving the potted plant352, thereby forming a covered potted plant 368. The covered pottedplant 368 is then placed on a conveyor 370.

A sleeving station 372, constructed much the same as the sleevingstation 184 described herein, is downstream of the conveyor 370 andcomprises an apparatus for applying a protective sleeve 374 to thecovered potted plant 368 to form a sleeved covered potted plant 376. Thesleeved covered potted plant 376 is placed onto a conveyor 378 forfurther processing. A gate station 380 is a gate 382 which serves todivert the sleeved covered potted plants 376 to a separate first lane383 and a separate second lane 384 of the conveyor 378 in preparationfor being placed in a carton. A gathering station 386 is a first gate388 and a second gate 390 for stopping and accumulating the sleevedcovered potted plants 376 in preparation for boxing. In an alternativeembodiment, either the gate station 380 or the gathering station 386, orboth the gate station 380 and the gathering station 386, are optional.

A carton feeding station 394 comprises a conveyor 396 for conveying orfeeding in direction 398 boxes or cartons 400 which will receive thesleeved covered potted plants 376. A boxing station 404 pushes orconveys the sleeved covered potted plants 376 into an empty carton 400for shipping. A closing station 408, if present, serves to close andsecure by taping, gluing or stapling each full carton 402 in preparationfor shipping. The closing station 408 could be automatic or could bemanually operated. All stations from the cover supplying station 362 tothe closing station 408, inclusive, comprise a single processing streamof the article packaging system 350. The article packaging system 350may comprise a second processing stream 412 for processing other pottedplants sorted at the sorting station 360.

Embodiment of Cover Supplying Stations

Turning now to FIGS. 28A-28B, the apparatus comprising the coversupplying station 362 is described in more detail. The cover supplyingassembly 364 is an apparatus having a denesting arm 416 for denesting apot cover 366 from a bin 418 and transferring the pot cover 366 to areceiving position 420 for receiving a potted plant 422. The denestingarm 416 has a grasping end 424 and a pivoting end 426. The grasping end424 has a shape adapted to fit around a base 428 of one of the potcovers 366 resting in the bin 418 of pot covers 366. The grasping end424 grasps the base 428 of the pot cover 366, in the preferredembodiment by a suctioning mechanism 430 and disengages the pot cover366 from the bin 418 of pot covers 366. The arm 416, now carrying a potcover 366, pivots in direction 432 to a position over the conveyor 370.The suction from the suctioning mechanism 430 is removed, therebyreleasing the pot cover 366 and placing the pot cover 366 on theconveyor 370 in preparation for receiving the potted plant 422. Theconveyor 370 may be equipped with guide walls 434 to guide the pot cover366 to a gate 436 to restrain the pot cover 366 in a stationaryposition. At this position, the potted plant 422 is disposed within thepot cover 366 to form the covered potted plant 368.

The gate 436 is opened. The covered potted plant 368 is releasedtherefrom and travels in direction 438 down the conveyor 370 to the nextstation. Meanwhile, the denesting arm 416 is pivoted away in direction440 and is returned to a position to retrieve the next pot cover 366.

Another denesting embodiment of the cover supplying station 362,illustrated in FIGS. 29A-29B, comprises a cover supplying assembly 364 ahaving a denesting arm 416 a for denesting one of the pot covers 366from the bin 418 and transferring the pot cover 366 to a receivingposition 420 a for receiving the potted plant 422. In this embodiment,the grasping end 424 a of the denesting arm 416 a comprises a suctioncup 424 a which places a suction on an outer bottom 442 of the base 428of the pot cover 366. The denesting arm 416 a pivots away from the bin418, and the pot cover 366 is removed from the bin 418 and carried to aconveyor assembly 444.

The conveyor assembly 444 comprises a first parallel belt 446 and asecond parallel belt 448 having a gap 450 extending lengthwisetherebetween. The grasping end 424 a of the denesting arm 416 a with thesuction cup 424 a is disposed in the gap 450 between the first andsecond parallel belts 446 and 448 of the conveyor assembly 444. As thebottom 442 of the pot cover 366 approaches the conveyor assembly 444,the suction from the suction cup 424 a is released and, as the graspingarm 424 a continues its downward motion, the pot cover 366 is restedgently on the conveyor assembly 444 and is carried by the first andsecond parallel belts 446 and 448 in direction 452 through the guidewalls 434 to the gate 436.

At the gate 436, the pot cover 366 is held stationary while the pottedplant 422 is disposed manually or automatically (non-manually) withinthe pot cover 366, thereby providing the covered potted plant 368. Thedenesting arm 416 a is then available to retrieve another pot cover 366.The cover supplying assemblies 364 and 364 a may be equipped withsensors (not shown) to regulate and control the operation of thedenesting arms 416 and 416 a and of the conveyor assemblies 370 and 444and gates 436.

Embodiments of Sleeving Stations

Turning now to FIGS. 24A-D, a sleeving apparatus 460 of the sleevingstation 372 will be described. The sleeving apparatus 460 comprises asleeve support assembly comprising a first wicket 462 and a secondwicket 464 which bear a set of sleeves 466. The sleeving apparatus 460is the same as a sleeving station 484 described herein except for themodifications described herein. Each of the first and second wicket 462and 464 extends horizontally for a distance, then bends downwarddiagonally. The sleeving apparatus 460 further comprises a suctioningtube 468 which applies a suction to a first side 470 of one of thesleeves 466 for loosening and separating the first side 470 from asecond side 472 of the sleeve 466 to provide an opening 474 at the upperend of the sleeve 466 (FIGS. 24A, 24B and 24D).

Air is forced into the opening 474 of the sleeve 466 from an inflatortube 476 and the sleeve 466 is thereby sufficiently inflated to receivethe covered potted plant 368. The inflator tube 476 is retracted by aninflator cylinder 477 or by another retracting device (FIG. 24B). One ofthe covered potted plants 368 is then deposited into the open sleeve466. The covered potted plant 368 may be automatically (non-manually)deposited in the sleeve 466 via a mechanism similar to that shown inFIGS. 17-18 for the sleeving station 184 described previously.Alternatively, the covered potted plant 368 may be deposited into thesleeve 466 manually by an operator. Alternatively, the potted plant 422without the cover 366 may be inserted into the sleeve 466, therebybypassing the cover supplying assembly 364.

The suction tube 468 is then retracted into a suction cylinder 478. Aresulting sleeved covered potted plant 480 will then slide, via gravity,down the first and second wickets 462 and 464 in direction 482 to aposition 483 over the conveyor 378 (FIG. 24C). The sleeved coveredpotted plant 480 may slide onto the conveyor 378 and, by the friction ofthe conveyor 378 underneath the bottom 442 of the base 428 of thesleeved covered potted plant 480, be carried by the conveyor 378 awayfrom the sleeving station 372.

Alternatively, the sleeving apparatus 460 may be equipped with adisengaging assembly comprising an extendable pushing arm 486 to pushthe sleeved covered potted plant 480 in direction 485 off the first andsecond wickets 462 and 464 onto the conveyor 378 (FIG. 24D). The sleevedcovered potted plant 480 is thereby conveyed upon the conveyor 378downstream and is ultimately packed into the carton 400. The extendablepushing arm 486 is then retracted by a pushing arm cylinder 488 inpreparation for the next sleeved covered potted plant 480. Operation ofthe sleeving station 372 may be regulated by sensing devices (not shown)opening the sleeve 466 in preparation for depositing a potted planttherein and for maintaining an even and regulated flow of sleevedcovered potted plants 480 on the conveyor 378.

The components of the sleeving apparatus embodiments are illustrated inFIGS. 15-19 and 24A-27B as isolated. However, it will be appreciated andunderstood by one skilled in the art that the components could be easilyand completely attached and assembled together to form a unifiedapparatus.

Embodiments of the Boxing Stations

Referring now to FIGS. 25-26, the sleeved covered potted plants 480 maybe boxed at the boxing station 404 immediately after leaving thesleeving station 372. In one embodiment, the boxing station 404comprises a boxing assembly 50Q and an extendable automatic pushing arm502 which, while pushing the sleeved covered potted plant 480 off thewickets 462 and 464, proceeds to push the sleeved covered potted plant480 in direction 504 into the open-sided box or carton 400 resting on anadjacent conveying system 506 (FIG. 25). Once the carton 400 is filled,the filled carton 402 (FIG. 22) is passed to the closing station 408 forclosing and securing. The pushing arm 502 is retracted by a retractingcylinder 508 in preparation for another sleeved covered potted plant480.

In another embodiment of the boxing station 404 (FIG. 26), a boxingassembly 510 has a pivotable automatic gripping arm 512 having agripping end 514. The gripping end 514 of the gripping arm 512 grips anupper portion 516 of the sleeved covered potted plant 480. The grippingarm 512 is retractable by a cylinder 518 attached to a pivoting brace520. The pivoting brace 520 is pivoted in direction 522 to a positionover a carton 400 a having an open upper side and the gripping arm 512lowers the sleeved covered potted plant 480 into the carton 400 a. Thecarton 400 a can then be closed and secured for shipping. Alternatively,rather than having the gripper arm 512 move the sleeved covered pottedplant 480 to a specific location in the carton 400 a, the gripper arm512 may only lift the sleeved covered potted plant 480 and the carton400 a may be automatically moved beneath the lifted sleeved coveredpotted plant 480 to be properly positioned to accept the sleeved coveredpotted plant 480 lowered thereinto.

Another embodiment of a boxing assembly is designated by the referencenumeral 530 and is shown in FIG. 33. Sleeved covered potted plants 480are individually directed into the open-sided carton 400 with a pushingarm 532 in direction 534. Sensors (not shown) detect the positions ofthe sleeved covered potted plants 480 already within the carton 400 andregulate the action of the pushing arm 532. Once the carton 400 isfilled, the carton 400 is closed and secured and moved in direction 536on the conveyor 396 for shipping. The empty open-sided carton 400 isdelivered as a replacement, in one embodiment by an automatic boxingdelivery assembly. The extendable pushing arm 532 is indicated in FIG.33 as being driven by a cylinder 538 but it is understood by one ofordinary skill in the art that there are other mechanisms for causingthe advancement and retraction of the pushing arm 532.

Preinsertion of Cover Into Sleeve

Turning now to FIGS. 27A-B and 30A-D, instead of the potted plant 422being covered by one of the pot covers 366 prior to insertion into thesleeve 466, the pot cover 366 may be preinserted into the sleeve 466prior to deposition of the potted plant 422 into the pot cover 366. FIG.27A indicates that the sleeve 466 is opened in a manner identical tothat described for sleeving apparatus 460 in FIG. 24A. The pot cover 366is then inserted in direction 550 into the opening 474 of the sleeve466. The suction tube 468 and inflation tube 476 are retracted and thepotted plant 422 is deposited in direction 550 into a cover/sleevecombination 552 in the same manual or automatic manner as that describedpreviously. The sleeved covered potted plant 376 then is conveyed by theconveyor 378 to the boxing station 404.

The pot cover 366 may be placed manually into the sleeve 466, but in thepreferred embodiment shown in FIGS. 30A-30D, a cover supplying apparatus364 b has a retractable cover denesting arm 554 having a suction end556. The suction end 556 of the denesting arm 554 retrieves one of thepot covers 366 from a bin 418 a of pot covers 366 (FIG. 30A). Thedenesting arm 554 is retracted by a cylinder 558 to remove the pot cover366 (FIG. 30B) from the bin 418 a. The pot cover 366 is transferred tothe sleeving station 372 (FIG. 30C) and is inserted into the previouslyopened protective sleeve 374 (FIG. 30D). Suction is removed from thesuction end 556 therein releasing the pot cover 366. The denesting arm554 is retracted, leaving the pot cover 366 within the sleeve 374 and inreadiness for insertion of a potted plant 422 therein using meansdescribed herein.

Embodiment of FIGS. 31-32

Turning now to FIGS. 31 and 32, another embodiment of the articlepackaging system is designated by the reference numeral 564. The articlepackaging system 564 has stations exactly as described for articlepackaging system 350 as shown in FIGS. 22-30 and 33 except that thearticle packaging system 564 employs the same cover supplying.apparatus, the same sleeving apparatus and the same boxing and closingdevices for all categories of potted plants sorted at the sortingstation. The advantage of the article packaging system 564 over thearticle packaging system 350 is that a single device performs eachparticular function such as sleeving for all grades or categories. Sinceduplicate apparatuses are not required for each function, the cost andthe space required for the overall system is reduced.

The article packaging system 564, as shown in FIG. 31, has a platform ortable 566 serving as a servicing station 568 supporting a set ofunsorted potted plants. A sorting station 570 employs a sorter (notshown) of the same type as packaging system 350 which inspects pottedplants 572 and sorts them in accordance with predetermined criteria suchas size, quality, or variety or any of a number of other criteria. Thesorter directs each sorted potted plant 572 to either a first parallelconveyor 574 or a second parallel conveyor 576. Potted plants 572 of aparticular category are then accumulated on the first conveyor 574 by arestraining gate 578 or on the second conveyor 576 by a restraining gate580 until a predetermined number of the type of potted plant 572 isaccumulated. When the predetermined number of sorted potted plants 572is accumulated, the appropriate gate 578 or 580 is opened.

The potted plants 572 are then conveyed to a covering station 584 wherea cover supplying apparatus 586 supplies a cover 588 and wherein thecover 588 is applied to the potted plant 572. Each covered potted plant590 in a particular category is then conveyed to a sleeving station 592where the covered potted plant 590 is deposited into a sleeve (notshown) in a manner exactly as described herein for the article packagingsystem 350 and its various embodiments. Sleeved potted plants 594 thusproduced are then conveyed to a boxing station 596 such as the boxingstation 404, or its other embodiments described for system 350, wherethe sleeved potted plants 594 are placed in cartons which are thenclosed and secured for shipment.

FIG. 32 shows a version of the article packaging system 564 having afirst conveyor 600 a, a second conveyor 600 b and a third conveyor 600 cwhich lead to the single sleeving station 592. The single sleevingstation 592 has rollers 601 and can be rolled or moved in direction 602or direction 604 between the first, second and third conveyors 600 a,600 b and 600 c manually or automatically for the purpose of supplyingsleeves 606 to potted plants 572 or covered potted plants 590 conveyedthereupon. In this way a single sleeving station 592 can supply sleeves606 to more than one of the first, second and third conveyor 600 a, 600b or 600 c and category of potted plants to reduce the cost and spacerequired for the system 564.

Alternatively, rather than having a plurality of separate conveyors suchas the first, second and third conveyors 600 a-600 c conveying coveredpotted plants 590 to the sleeving station 592, a single conveyor havinga plurality of parallel lanes (not shown) could be used. Each parallellane would have a separately regulated. gate (not shown) for allowingaccumulation and passage to the sleeving station 592 of a predeterminednumber of potted plants or covered potted plants 590.

The single sleeving station indicated in FIG. 32 is shown as havingseparate conveyors 608 a-608 c for conveying the covered potted plants590 to the appropriate boxing station 596. Each conveyor 608 a-608 ccould direct the sleeved potted plants to a single conveyor (not shown)leading to a single boxing station. Alternatively, each conveyor 608a-608 c could direct the sleeved potted plants to a separate boxingstation.

As described herein for article packaging system 350, the articlepackaging system 564 could be modified in a number of ways. For example,the pot cover could be applied to the potted plant prior to accumulationon the first and second conveyors 574 or 576 by restraining gates 578 or580, respectfully; or, the pot cover could be placed into the opensleeve 606 prior to the introduction of the potted plant into the sleeve606, as indicated in tie embodiment shown in FIGS. 27A-B.

Embodiment of FIG. 34

Referring now to FIG. 34, another embodiment of the article packagingsystem referred to by the reference numeral 610 is illustrated. Thearticle packaging system 610 is constructed exactly as described forarticle packaging systems 10, 350, or 564 or modifications thereofexcept that a decorative pot cover is directly formed about the outersurface of a potted plant 612 using an appressing cover formingapparatus such as a cover forming apparatus 614 to form a covered pottedplant 616 at a point prior to application of a sleeve to the pottedplant 612. The cover forming apparatus 614 appresses a sheet of material(not shown) about the external surface of the potted plant 612 to formthe covered potted plant 616 having a cover which may or may not bebonded to the external surface of the potted plant 612, as describedherein.

The cover forming apparatus 614 which could be used, for example, is onedescribed in U.S. Pat. No. 5,291,721 entitled “Cover Forming ApparatusHaving Pivoting Forming Members”, the specification of which is herebyspecifically incorporated herein by reference. This does not exclude theuse of other types of cover forming apparatuses adapted for forming acover about the outer surface of a potted plant to form the coveredpotted plant 616.

After the potted plant 612 has been covered by the cover formingapparatus 614, the covered potted plant 616 is transferred to a conveyor618 moving in direction 620 toward a sleeving station exactly the sameas other sleeving stations previously described herein. The relocationof the covered potted plant 616 from the cover forming apparatus 614 canbe accomplished manually or automatically such as by a transfer device621 having an extendable pushing arm 622 or by some other device adaptedfor moving the covered potted plant 616 to the conveyor 618.

Changes may be made in the combinations, operations and arrangements ofthe various parts and elements described herein without departing fromthe spirit and scope of the invention as defined in the followingclaims.

What is claimed is:
 1. A method of packaging a potted plant comprisingthe steps of: providing a potted plant having an exterior surface;providing an automatic sleeving apparatus for automatically applying asleeve to the potted plant; transferring the potted plant to theautomatic sleeving apparatus; automatically applying a sleeve about thepotted plant by non-manually disposing the potted plant into the sleeveto form a sleeved potted plant; and bonding the sleeve about the pottedplant via a bonding material.
 2. The method of claim 1 comprising theadditional step of sorting the potted plant into one of at least twogrades in accordance with a predetermined grading criterion.
 3. Themethod of claim 2 wherein the step of sorting the potted plant occursbefore the step of automatically applying the sleeve.
 4. The method ofclaim 2 wherein the step of sorting the potted plant occurs after thestep of automatically applying the sleeve.
 5. The method of claim 2wherein the step of sorting the potted plant comprises using anautomatic sorting apparatus to sort the potted plant.
 6. The method ofclaim 1 wherein the automatic sleeving apparatus comprises an apparatusfor automatically opening the sleeve to provide an open sleeve forreceiving the potted plant.
 7. The method of claim 1 comprising theadditional step of sealing an upper portion of the sleeve of the sleevedpotted plant.
 8. A method of packaging a potted plant comprising thesteps of: providing a potted plant having an exterior surface; providingan automatic sleeving apparatus for automatically applying a sleeve tothe potted plant; transferring the potted plant to the automaticsleeving apparatus; automatically applying a sleeve about the pottedplant, by non-manually disposing the potted plant into the; sleeve toform a sleeved potted plant; and bonding the sleeve about the pottedplant via a band.
 9. The method of claim 8 comprising the additionalstep of sorting the potted plant into one of at least two grades inaccordance with a predetermined grading criterion.
 10. The method ofclaim 9 wherein the step of sorting the potted plant occurs before thestep of automatically applying the sleeve.
 11. The method of claim 9wherein the step of sorting the potted plant occurs after the step ofautomatically applying the sleeve.
 12. The method of claim 9 wherein thestep of sorting the potted plant comprises using an automatic sortingapparatus to sort the potted plant.
 13. The method of claim 8 whereinthe automatic sleeving apparatus comprises an apparatus forautomatically opening the sleeve to provide an open sleeve for receivingthe potted plant.
 14. The method of claim 8 comprising the additionalstep of sealing an upper portion of the sleeve of the sleeved pottedplant.
 15. A method of packaging a potted plant comprising the steps of:providing a potted plant having an exterior surface; providing anautomatic sleeving apparatus for automatically applying a sleeve to thepotted plant; transferring the potted plant to the automatic sleevingapparatus; automatically applying a sleeve about the potted plant bynon-manually disposing the potted plant into the sleeve to form asleeved potted plant; and bonding the sleeve about the potted plant viaa tie.
 16. The method of claim 15 comprising the additional step ofsorting the potted plant into one of at least two grades in accordancewith a predetermined grading criterion.
 17. The method of claim 16wherein the step of sorting the potted plant occurs before the step ofautomatically applying the sleeve.
 18. The method of claim 16 whereinthe step of sorting the potted plant occurs after the step ofautomatically applying the sleeve.
 19. The method of claim 16 whereinthe step of sorting the potted plant comprises using an automaticsorting apparatus to sort the potted plant.
 20. The method of claim 15wherein the automatic sleeving apparatus comprises an apparatus forautomatically opening the sleeve to provide an open sleeve for receivingthe potted plant.
 21. The method of claim 15 comprising the additionalstep of sealing an upper portion of the sleeve of the sleeved pottedplant.
 22. A method of packaging a potted plant comprising the steps of:providing a potted plant having an exterior surface; providing anautomatic sleeving apparatus for automatically applying a sleeve to thepotted plant; transferring the potted plant to the automatic sleevingapparatus; automatically applying a sleeve about the potted plant bynon-manually disposing the potted plant into the sleeve to form asleeved potted plant; and bonding the sleeve about the potted plant viaa ribbon.
 23. The method of claim 22 comprising the additional step ofsorting the potted plant into one of at least two grades in accordancewith a predetermined grading criterion.
 24. The method of claim 23wherein the step of sorting the potted plant occurs before the step ofautomatically applying the sleeve.
 25. The method of claim 23 whereinthe step of sorting the potted plant occurs after the step ofautomatically applying the sleeve.
 26. The method of claim 23 whereinthe step of sorting the potted plant comprises using an automaticsorting apparatus to sort the potted plant.
 27. The method of claim 22wherein the automatic sleeving apparatus comprises an apparatus forautomatically opening the sleeve to provide an open sleeve for receivingthe potted plant.
 28. The method of claim 22 comprising the additionalstep of sealing an upper portion of the sleeve of the sleeved pottedplant.